MIL COTS POWER
CONVERSION PRODUCTS COMMERCIAL OFF THE SHELF
UNIQUELY QUALIFIED
OVERVIEW Military applications present challenges to power conversion products by the very nature of the harsh environment they must operate in. They are first required to demonstrate reliability during all test phases, but more importantly in the battlefield, performing in the demanding application itself- where it counts. Reliability is the key driver in mission critical applications and for over 50 years, AstrodyneTDI has demonstrated a solid history and reputation in the military marketplace, providing solutions for many of today’s sophisticated weapon,
POWER SUPPLIES LOW POWER / HIGH POWER
ENVIRONMENTALLY SEALED
command and control systems. These power systems are designed to meet stringent MIL STD specifications and endure the harsh environmental and electrical requirements of today’s battlefields. Today, Astrodyne TDI COTS can assist in low and high power conversion of AC to DC, DC to AC , DC to DC as well as all EMI filter requirements in between. Power Supplies - Filters - Inverters - Converters - UPS - Systems Low Power - High Power - Filters - Ruggedized - Environmentally Sealed -
INVERTERS
CONVERTERS
Power Conversion Systems
BENEFITS OF COTS/MODIFIED COTS Many military contractors worldwide are sensitive to costs , design cycles and performance. There are many applications with requirements that need to withstand the rigors and extremes of mother nature, where most off the shelf power products designed for commercial use would not UPS SYSTEMS
EMI FILTERS
endure. Many Astrodyne TDI power products were engineered specifically as platforms for industrial, automotive and military applications so the design effort using Astrodyne TDI COTS is greatly reduced not only internally, but also for contractors and integrators who need to qualify to MIL specifications to suit specific ruggedness and environmental requirements. The use of COTS results in overall reduction of cost and development time,faster deployment of solutions and shorter lead times
ELECTRONIC LOADS
versus a customized built-to-order solution. Reduce Cost - Reduce Development Time - Speed Time to Market Shorter Lead Times - Low Risk Count on AstrodyneTDI for all of your military COTS and modified COTS requirements
MANUFACTURING IN USA Astrodyne TDI offers US manufacturing along with the benefits of global sourcing, when acceptable. Our manufacturing facilities are fully certified to ISO9001: 2008 and ISO 14001:2004 RoHS.
HASS: Highly Accelerated Stress Screening (HASS) is performed on 100% of all Astrodyne TDI high power, production ready COTS products (each and every product produced). More stressful than Mil-Spec Environmental Stress Screening (ESS), HASS subjects units under test to a rigid temperature, shock vibration and electrical parameters profile.
HALT: Highly Accelerated Life Testing (HALT) is pre-production process performed to uncover limitations in product design, component selection and manufacturing that would not otherwise be found through conventional qualification methods. The process subjects the unit to progressively higher stress levels, incorporating thermal dwells, rapid temperature transitions, vibration, and a combination of temperature and vibration to precipitate inherent defects. Astrodyne TDI performs HALT on each and every high power design.
• 200,000 Sq. Ft. • 6 SMT Lines • PTH Assembly & Wave Solder • PCB In-Circuit Test and Sub-Module Test • HASS – Highly Accelerated Stress Test • ISO 9001:2000, 14001:2004 RoHS • Overseas locations share common manufacturing and test equipment and processes with USA • Easy transition from pilot production to volume production • Redundant manufacturing capability
100% HASS TESTED
VERSATILE AC-DC POWER
MODULAR FLEXIBLE
MERCURY SERIES AIR COOLED SUPPLIES, SINGLE PHASE SWAPPABLE - SCALABLE - WIDE RANGE - DIGITAL CONTROL
SWAPPABLE PROGRAMMABLE
Mercury 2U modules with HOT-SWAP shelf The Astrodyne TDI 3.8kW Mercury-Flex is the perfect rectifier solution for applications that require a flexible digitally controlled industrial power supply with a universal 90 to 264VAC 50/60Hz single phase input, and a wide choice of DC output voltage ranges. Standard Mercury varieties of 28V, 56V, 85V, 125V and 400V are available. Using digital CAN-Bus commands, Mercury-Flex can be field programmed to operate in a constant voltage, constant current, or constant power mode. The digital readback feature provides output voltage and current values, operating temperature, and protection alarm status.
LiquaBlade™ 1U Module
LIQUABLADE™ LIQUID COOLED SUPPLIES; UNIVERSAL THREE PHASE SWAPPABLE - SCALABLE - WIDE RANGE - DIGITAL CONTROL The LiquaBlade™ Series are the latest breed of industrial grade, high power three phase AC-DC power supplies engineered by Astrodyne TDI. These rectifiers combine advanced DC power processing, the latest silicon carbide semiconductors, patented liquid cooling and sophisticated microprocessor controls, resulting in up to 16 kW per blade of power in a single 1U (1.75” height) rack style package. The high frequency switch-mode design employed in LiquaBlade™ offers full active power factor correction, near unity power factor and excellent output responsiveness. The wide AC input range of 380480V 50/60Hz permits universal three phase usage without the need of an external step down transformer. LiquaBlade™ is fully programmable - the perfect flexible high power supply solution when noise needs to be kept at a minimum or where conductive air debris may be present.
LIQUABLADE™ ACCESSORIES
EXAMPLE LAYOUT DEMONSTRATING (3) INDEPENDENT LIQUABLADE™ ZONES WITH VARIOUS POWER LEVELS 16.5KW x 3
SYSTEM CONTROLLER
Zone 1
Monitor, Control and Administration
Blade 1
- Interfaces to LiquaBlade™ CAN Controlled Power Supplies / Rectifiers
Blade 2
- 1U Rack Height
Blade 3
16.5KW x 2
Zone 2
- 6 Analog Interface D-Sub connectors for control of up to 6 “power zones”
Blade 4
- Configurable via the Ethernet Interface, 0-10V analog interface or both
Blade 5
16.5KW x 1
- Integrated Web Server - N+1 Redundancy Enabler for LiquaBlade™ Modules
LIQUABLADE™ WITH EASY SWAP SHELF ASSEMBLY
CanBUS
- 10 Base T Ethernet Interface
Zone 3 Blade 6
Controller
LiquaBlade™ Module
Ethernet Host Computer
3 Ph AC Power Guide Pins Shelf Assembly with Rail Guide
DC Terminals Cooling Connections
RACK SYSTEMS
Astrodyne TDI can offer engineered system solutions, when required. - Rack Assemblies with Complete Busing/Plumbing/Power Distribution
1U HEIGHT ENABLES SIGNIFICANT SPACE SAVINGS
- AC Input Circuit Breaker Panel - Multi-Zone System Controls - Self-Contained Heat Exchange System - Dew point Monitoring for Anti-Condensation Control
Up to 500 kW in a single 52” rack system
INDUSTRIAL DC-AC INVERTERS SWAPPABLE - SCALABLE - 24V/48V and 120V/220VAC VERSIONS LCE Shelf Assembly with back plane LCE
The LCE inverter is parallelable, hot swap compatible and supports N+1 redundancy. The interlocking cam actuated handle turns power off before removal and power on after insertion for glitch-free hot swapping of inverter units. Cabinets, shelves and controllers are available for large and complex indoor and outdoor systems. Example of 10kW UPS System with Lithium Ion Battery Backup
The LCE series is fully scalable, permitting multiple modules to be paralleled in single phase (up to 36KVA) or three phase applications (up to 20KVA per phase). Full power can be provided over an ambient temperature rang of –20 to +55°C. For low power inverters (500VA), look to the LPE Series (1U height)
UPS AND BATTERY BACKUP
e-link controller
The LCE and Mercury Series are field proven in MIL applications such as UPSs and backup power in both ground and sea. Utilizing Mercury power supplies, LCE Inverters and E-Link Controllers for status reporting and remote administration, Astrodyne TDI has a library of system offerings to match your UPS and backup requirements. For battery backup, Astrodyne TDI also offers blind Mate /hot plug battery backup units (500W-Hr per U of rack space) for easy installation/removal and expansion. Blind mate/hot plug battery backup unit • Designed for standard 19” equipment racks -220/230VAC 1-ph or 3-ph Input Power -120/240VAC Output Power • Scalable and Expandable • Hot swappable • “Mercury” Rectifier based AC-DC Power Supply • LCE (or LPE) Inverters DC-AC Conversion • “eLink” Monitoring and SNMP Reporting Module • 1U Lithium Ion battery box with charge management(500W-Hr per U) Example of 20 kW UPS System with Lithium Ion Battery Backup
SPECIALIZED PRODUCTS ICCP: IMPRESSED CURRENT CATHODIC PROTECTION RECTIFIER SYSTEMS
AN APPROVED
MILITARY SUPPLIER
2.5kW, field serviceable system
15kW, field serviceable system
with convection cooled ESPM sealed
with on-board liquid cooled rectifier,
rectifier, encapsulated in either silicon
heat exchange system with pump and
RTV or oil
reservoir, IP65 grade
PORTABLE POWER DISTRIBUTION AC-DC Supplies with DC-AC inverter plus circuit breakers and local indication in MIL transit case
ELECTRIC AND HYBRID VEHICLE LiquaCore Series Liquid Cooled DC DC Converters for electric vehicle applications; 400 to 12VDC, 400 to 24VDC or 700 to 24VDC varieties available
STATIONARY DC POWER SYSTEM 440/480VAC 3-Phase, 3-Wire Input, 15kW DC output with Mercury rectifiers, circuit breakers and metal case for 19� rack assembly
EMI FILTERS
EMI FILTERS • MIL-STD-461, RTCA/DO160, MIL-STD-810 • EMI FILTERS • EMP/HEMP FILTERS (MEET MIL-STD-188-125-1 POINT OF ENTRY REQUIREMENTS FOR SHORT/ INTERMEDIATE PULSES)
• FACILITY/SHIELDED ROOM POWER LINE FILTERS • DATA/COMMUNICATION/ CONTROL LINE FILTERS • TUBULAR FILTERS FEATURING HIGH QUALITY FEED-THROUGH CAPACITORS (14000 SERIES)
• FREQUENCIES RANGING FROM 47 TO 880 HZ
Astrodyne TDI has over two decades of experience in design, development and manufacturing of a complete range of AC and DC EMI/ RFI/ EMC filters for military and aerospace applications. Our standard line of military EMI Filters provide off-the-shelf performance for MIL-STD-461 and RTCA/DO-160 applications. Our standard offerings are also complemented by a diverse capability to design and build customized and custom filters and configurations. Most MIL-COTS EMI filters are designed for ambient temperature of -40°C to +70°C (-40°F to +158°F) and operate in this range without any de-rating. Some of our single phase rugged COTS EMI filters are designed for an extended ambient temperature of -40°C to +80°C (-40°F to +176°F). All Military EMI Filters have operating temperate range up to 100°C (212°F) and storage temperature down to -55°C (-131°F).
ENCAPSULATED BRICK POWER MODULES Encapsulated brick power modules are frequently chosen for use as components in commercial off the- shelf military power system designs. Outstanding electrical performance, coupled with mechanical packaging features such as insulated metal substrates, planar magnetics and thermally conductive potting make RO the bricks of choice for high performance, high power density systems. Electrical performance features such as high efficiency and superior thermal design make the RO bricks easy to cool in closed box applications, where air flow is limited, or in any such applications where ambient temperatures are high.
AC TO DC
DC TO DC
PFC 180 180W 1/4 Brick
SV24 24V Input 300-350W 1/Brick
PFC 375 375W 1/2 Brick
SV48 48V Input 300-350W 1/2 Brick
PFC 650 650W 3/4 Brick
nV300 300V Input 1/2 Brick 120W
SMV SERIES OF BOARD MOUNT 500W AC/DC with PFC Full Brick
uV300-164 300V Input 3/4 Brick 300W
ENCAPSULATED
BRICK
POWER MODULES
PERFORMANCE With proper implementation, Astrodyne TDI COTS Power modules and filters have demonstrated typical performance specifications of:
PROTECT AGAINST: • CONDUCTIVE DEBRIS INFUSION • HIGH TEMPERATURE & CONDENSING HUMIDITY • INDUSTRIAL PROCESS BYPRODUCTS • -IP67, NEMA-3, NEMA-4, NEMA-6 HAZARDOUS LOCATION
TEMPERATURE: -40˚C to +65˚C
ALTITUDE: 10,000 ft., MIL-STD-810F, Method 500.4-1
HUMIDITY: 100%RH
SHOCK: MIL-STD-810F, Method 516.5, Para. 2.2.2, Procedure 1, Functional Shock
SALT SPRAY: MIL-STD-810F, Method 509.4-1 FUNGUS: MIL-STD-810F, Method 508.5-1
VIBRATION: MIL-STD-810F, Method 514.5A, Para. 2.4.1, Catagory 24 - All material - minimum integrity test
SAND AND DUST: MIL-STD-810F, Method 510.4-1
EMI: MIL-STD-461
As an approved military supplier to the US Department of Defense, Astrodyne TDI is compliant to the regulatory requirements as mandated by all defense branches. HINGED OUTDOOR ENCLOSURES solar and rain resistant
OIL FILLED ENCLOSURES for saturated or dust environments
Electrical De-rating Guidelines per NAVSO P- 3641A
PORTABLE ENCLOSURES shock resistant, water tight
DC ELECTRONIC LOADS Driven by the need to test our DC supply designs, Astrodyne TDI developed our own line of electronic loads based on a paralleled power MOSFET architecture, analog and/or digital signal processing feedback loop control, extensive measurement functions, thermal management and synchronized master/slave paralleling control mode technology. Astrodyne TDI gained extensive and valuable knowledge in developing rugged and reliable products, where today we retain a leadership role in the DC load market for the military segment. Astrodyne TDI Dynaload® high power density DC electronic loads are used for a wide variety of power source test requirements ranging from DC power supplies to fuel cells to batteries, and more. Product offerings range from single channel air or liquid cooled loads, to multichannel loads to multi-channel systems to suit your specific requirements.
• • • • •
Single channel air cooled Multi-channel air cooled Single channel water cooled Master/Slave functionality Rack Systems air cooled and water cooled (120kW and higher)
KEY FEATURES • • • • • • • • • •
Ultra fast slew rate Flexible duty cycle Full scale range switching (three selectable) Assortment of performance indicators Exceptional self-protection circuitry Over voltage (OV) Over current (OC) Reverse polarity Thermal protection (with auto-disconnect) Simultaneous LED display of voltage current and power • 10+ Memory Presets for Saving Load Profiles • Remote voltage sense • 120V/230VAC 50/60Hz • Ethernet, IEEE488 GBIP, RS232 plus 0-10V analog control • Labview drivers
HIGH POWER DENSITY
CONTACT ASTRODYNE TDI TODAY WITH YOUR SPECIFIC REQUIREMENTS.
www.AstrodyneTDI.com | +1 908-850-5088
POWER. EVERYTHING DEPENDS ON IT. When the need for power conversion is at its most demanding…its most critical… for over 50 years, the solution has been Astrodyne TDI. Today, our unmatched experience across multiple industries enables us to deliver a wide range of power-based technology solutions for some of the most well-known companies in the world. From off the shelf standard power supplies and electronic loads to complete customized power systems, the solution is always as close as Astrodyne TDI.
NOW YOU HAVE POWER.
© Copyright 2016, Astrodyne, Inc This document is believed to be correct at time of publication and Astrodyne, Inc accepts no responsibility for consequences from printing errors or inaccuracies. Specifications are subject to change without notice.